Protective packaging

ABSTRACT

There is provided a method of manufacturing a protective packaging structure comprising the steps of providing a moulded structure comprising an attachment surface, the moulded structure including a recessed portion defining a shock absorbing region, applying the moulded structure to a packaging substrate using the attachment surface, and configuring the substrate to form the protective packaging structure. A protective packaging comprising a moulded structure based on paper plate technology is also disclosed.

BACKGROUND

Protective packaging can be used to pack a range of products including hardware products, such as printers, in order to prevent damage to the products in the event of an external impact or vibration force, For example, protective packaging prevents damage to a product if it is accidentally dropped during transportation, or a vibration from transportation is transferred to the outside of the packaging, Packaging cushions can be provided around a product to absorb any impact forces exerted onto the product.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of certain examples will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example only, a number of features, and wherein:

FIGS. 1A-E are schematics of a moulded structure for protective packaging according to an example;

FIG. 1F is a schematic of nesting or stacking a moulded structure according to an example;

FIGS. 2A and 2B are schematics of protective packaging according to an example;

FIGS. 3A-C show an example of a production line for assembling protective packaging according to an example;

FIGS. 4A-C are flow charts each showing a method for manufacturing protective packaging according to an example;

FIGS. 5A and 5B are schematics of attachment of a moulded structure according to an example;

FIG. 6 is a schematic of a moulded structure for protective packaging according to an example;

FIGS. 7A and 7B are schematics of a moulded structure for protective packaging according to an example;

FIGS. 7C and 7D are schematics of a moulded structure for protective packaging according to an example;

FIG. 8A is a schematic of protective packaging according to an example;

FIG. 8B is a schematic of protective packaging according to an example;

FIG. 8C is a schematic of an arrangement of moulded structures for protecting a hardware product according to an example;

FIG. 9 is a schematic of a moulded structure for protective packaging according to an example;

FIG. 10A is a schematic of a moulded structure for protective packaging according to an example;

FIGS. 10BD are schematics of a moulded structure for protective packaging according to an example; and

FIGS. 11A and 11B are schematics of nesting or stacking a moulded structure according to an example.

DETAILED DESCRIPTION

In the following description, for purposes of explanation, numerous specific details of certain examples are set forth. Reference in the specification to “an example” or similar language means that a particular feature, structure, or characteristic described in connection with the example is included in at least that one example, but not necessarily in other examples.

Packaging cushions can be provided as protective packaging inside of a corrugated box for example, and may include soft materials and ribs. Cushions can be made from moulded pulp, corrugated paper, polystyrene (known as Styrofoam, EPS) or expanded polyethylene (EPE) or other material.

Reinforced protection can be provided at the corners of packaging, for example by gluing, to improve protection. Shock absorbers may be adjustable, via slits in EPS, to better shape the protective packaging to a product. For example, cushioning boards made of paperboard can be connected to a packaging box with hinges to protect items such as glass bottles, where the cushioning boards are wrapped around the bottles. Other paper-based shock absorbers may be cut to shape to fit onto packaging, such as a cardboard box, by gluing to form the protective packaging.

The disclosure relates to paper-based protective packaging. Protective packaging may include paper-based moulded structures or cushions for protecting hardware products that are packed inside the packaging. The moulded structures may resemble cushioning ribs that are manufactured using paper-plate technology. The moulded structures may protect a product along a flat region of the product or an edge or corner of the product.

In an example, the moulded structure is moulded in an I-shaped form, such as that shown in FIGS. 1A and 1B. The structure comprises a first section 110 having a recessed region 115 and a second section 120 having a recessed region 125. An intermediate section 130 is disposed between the first section and the second section. The moulded structure comprises an attachment surface 140 which may be formed at or around a periphery of the first section and second section. The intermediate section may comprise a hinge 145 about which the first and/or second section can pivot. The intermediate section may comprise a sloped surface 150 on the first section or first shell and a corresponding sloped surface 160 on the second section or second shell. The attachment surface may comprise the sloped surfaces. In the example shown, when the first section is pivoted about the hinge the sloped surfaces 150, 160 connect, hence closing the open V-shape of the intermediate section. In the open configuration shown in FIGS. 1A and 1B, both the first and second sections extend along the same direction 190.

FIGS. 1C and 1D show the moulded structure in a closed configuration in which the first section has been rotated about the hinge 145. In the closed configuration, the second section extends along a first direction 190 and the first section extends along a second direction 195. The first direction may be substantially perpendicular to the second direction, or positioned at another angle. The moulded structure may be substantially L-shaped. The first section and second section may be linearly shaped with the intermediate section forming a corner between the first section and second section.

FIG. 1E shows the moulded structure provided with a notched region 197. The notched region may be provided to allow a better flow of the paper material in the hinge-area during the moulding process (unlike vacuum moulding of plastics paper which cannot be stretched/expanded). Although not shown in FIGS. 1A-D, a notch may be provided in the moulded structure.

Each recessed region may define a hollow shell such that the moulded structure can be nested within a further moulded structure. FIG. 1F is a schematic showing the nesting or stacking of moulded structures according to an example.

FIGS. 2A and 2B show a protective packaging in which moulded structures are attached to a package or sleeve or shell. The moulded structures may be arranged on the inside of the protective packaging around a product contained within the packaging. An outer layer of packaging may also be provided for further protection or reinforcement during storage or shipping. In an example, the outside shell or tray holding the moulded structures may comprise cardboard or corrugated board, where the arrangement of the sheet facing the outer shipping carton can add to the compressive stacking strength of that outer shipping carton. Thus, a shipping carton with lower strength and costs may be selected in conjunction with these extra shells to achieve the same overall compressive stacking strength as compared to standard cushions.

FIGS. 2A and 2B show assembly steps of how ribs are glued or stapled to a cardboard or corrugated sheet and then folded into a tray acting as a left and right end-cap for an inkjet printer according to an example, The protective packaging comprises a plurality of moulded structures attached to the outer surface of a package, such as a cardboard box. The moulded structures may be arranged on all sides of the package. In regions of the package that are known to be weaker and less able to withstand an impact force, such as a periphery of the box, additional moulded structures may be provided for reinforcement or enhanced protection. A product to be protected is placed within the protective packaging such that it is surrounded by the moulded structures. For example, the protective packaging may form an end-cap having the moulded structures for protecting a printer or other hardware component from external impact forces during transit,

In an example, the moulded structures are mass produced and are provided into pre-defined cavities (by hand or dispensers) along a conveyor-like production line. A half-box may then be applied on top of the arranged moulded structures as a flat sheet, The flat sheet is pressed onto adhesive on the attachment surfaces of the moulded structures, For example, hot-melt glue or starch-based glue can be applied on the attachment surfaces or rib-flanges. The flat sheet of the box and the moulded structures are pressed together. A box can then be formed by folding the flat sheet into a half-box or an end-cap.

FIGS. 3A-C show an example of a production line for providing protective packaging according to an example. In particular, moulded structures may be placed in depressions as shown in FIG. 3B before a flat sheet of cardboard is placed over the moulded structures as shown in FIG. 3C. In this example, there is shown an assembly process according to an example, in which cushioning ribs are pre-positioned in an array of assembly trays in a conveyor system (or a rotary table system). The ribs and the corrugated sheet may be inserted manually by operators or automatically by robotic arms or dispensers. FIGS. 3A-C do not show details of a glue-application step. There are many different ways to apply the glue, for example the glue may be applied on the flanges, on the flat sheet or substrate, with a tool (such as a flexo-printing plate or silk printing plate), or by a robotic arm.

A method for moulding a moulded structure comprising a layer(s) or sheet(s) of paper for protective packaging according to an example will now be described.

FIG. 4A is a flow chart of a method for moulding a moulded structure for protective packaging according to an example. At block 410 there is a step of providing a moulded structure comprising an attachment surface, the moulded structure including a recessed portion defining a shock absorbing region. At block 420 there is a step of applying the moulded structure to a packaging substrate using the attachment surface, At block 430 there is a step of configuring the substrate to form the protective packaging structure, The attachment surface may be provided around a periphery of the structure. At block 440 the substrate may be configured whereby to conform to an outer dimension of an article to be packaged.

In an example, a pre-defined moulding template may be provided that is product or packaging specific. The moulded structure is applied to packaging to form protective packaging for protecting a product during transportation.

A plurality of moulded structures may each be manufactured in a respective pre-defined moulding template on a production line. The method may further comprise the step of inserting a plurality of moulded structures into respective pre-positioned depressions in an assembly tray of a conveyer system or rotary table system. The moulded structures may be of the same type or can be a combination of different types or sizes. The moulded structures may be inserted manually by operators or automatically by robotic arms or dispensers. The method may further comprise the step of arranging a flat sheet of corrugated cardboard over the moulded structures. The flat sheet may be pressed onto adhesive and subsequently onto the attachment surfaces of the moulded structures. The method may further comprise the step of folding the flat sheet to form a half-box having the moulded structures attached thereto. The step of applying may comprise one or more of: gluing; stapling; and interconnecting.

FIG. 5A shows attachment of a moulded structure according to an example. The moulded structure may be glued on a flange or stapled at a flange. In the example of FIG. 5A is shown different methods of how a rib can be connected to a corrugated sheet, for example using glue or staples or interlocking. The corrugated sheet may be provided on either side of the flange. The flange may be sandwiched between two corrugated sheets or a corrugated sheet having holes and allowing nesting of a plurality of moulded structures for space-saving storage and delivery. FIG. 5B shows a rib section that is cut open for better visibility. For example, two ribs with two different depths inside each other, where the two ribs add to the total protection in this area can be provided. The amount of energy which the deformation of two nested ribs can take on a drop is higher and having the ribs with two different depths will generate progressive cushion-performance curves.

FIG. 6 shows non-hinged moulded structures which can be designed with a specific shape to fit a particular product. In an example, moulded structures are attached to a flat surface.

FIGS. 7A and 7B are schematics of a moulded structure 700 for protective packaging according to an example. The moulded structures may be attached on an inner surface of packaging adjacent the product to be protected.

In the example of FIG. 7A is shown the surface of the moulded structure that receives an external impact force. The structure comprises a first section 710 and a second section 720 and an intermediate section or region 730 located between the first and second sections.

FIG. 7B shows an inner surface of the moulded structure arranged such that it faces towards the product to be protected. The moulded structure comprises two shells forming the first and second sections, The first section comprises a first recessed region 715 and the second section comprises a second recessed region 725. The structure comprises an attachment surface 740 which may be formed at or around a periphery of the first section and second section.

FIG. 7C shows a moulded structure 700 for protective packaging according to an example. The structure comprises a first section 710 having a recessed region 715 and a second section 720 having a recessed region 725, Each recessed region is provided facing towards a product to be protected, with a shell forming the first and second sections facing outwards and away from the product such that the shell forming the first and second sections are the point of contact receiving an external impact force. The structure further comprises an intermediate section 730 disposed between the first section and the second section. As shown in FIG. 7D, the first and second sections may be of different lengths or sizes. An impact force may comprise a shock and/or vibration.

In an example, the moulded structure comprises an attachment surface 740. The attachment surface may be formed at or around a periphery of the first section and second section. The attachment surface or flange may be provided as a flat surface or flange that is suitable for attaching the moulded structure onto a package, for example using adhesive. The attachment surface may extend beyond an intersection with the shell forming the first and second sections such that the attachment surface protrudes beyond the shells, This provides a larger area for applying the moulded structure onto packaging to provide a more reliable attachment. This also allows for the application of more pressure during the gluing process without deforming the ribs.

In the example of FIG. 7C, the intermediate section also comprises a recessed region to protect a corner of protective packaging. An inside corner 745 is provided that may have a surface that is suitable for conforming to a package or for attachment to a package, The inside corner may be suitable for hugging the corner of a package.

The intermediate section allows the first section to be arranged at an angle to the second section. The moulded structure may be substantially L-shaped. For example, the angle between the first and second sections may be around 90 degrees. The first and second sections may extend in two directions 750, 760 that are angled to one another. The moulded structure can be attached to a corner of packaging. As such, the moulded structure is suitable for absorbing an impact force at a corner of protective packaging, An impact of a product drop will have the energy being absorbed by the deformation of the papers in the recessed regions. The moulded structure may act like a cushion under an external force to cause one or more the sections to cave into the recessed region such that the impact force is absorbed.

The structure is moulded using paper-plate manufacturing technology in which a layer(s) or sheet(s) of paper is used. The paper-plate manufacturing process involves a moulding process utilizing pressure and heat using sheets of paper (as opposed to pulp). Paper thicknesses can range from 50 gsm to 1000 gsm. The tool for the moulding has to consider a maximum depth, angles of the sides and surfaces of the moulded structure and the flow of paper from a flat sheet to a moulded shape. The moulding template may be provided to conform to a packaging onto which the moulded structures are attached to form the protective packaging.

The moulded structure shown in FIG. 7C may be attached to the outside of packaging on an outer surface on an opposite side of the packaging to the product, The moulded structures may alternatively or additionally be attached on the inside of packaging on an inner surface adjacent the product.

In an example a moulded structure or cushioning rib has six faces, twelve edges and eight corners. The moulded structure protects a product from external shock and vibration.

The protective packaging may comprise moulded structures that form paper-based ribs in either a fixed shape or an adjustable shape or a hinged shape. The adjustable moulded structure may be selected or modified to conform to a package or product shape. The moulded structures may be generally L-shaped and may comprise at least one hinge such that the angle of the L-shaped rib is adjustable. The moulded structures have recessed regions. As such, the moulded structures or ribs are formed of a shell of a layer or layers of paper.

The first section and/or the second section of the moulded structure may be provided to any desired length to suit the product to be protected. For example, the first section may be of the same or a different length to that of the second section. In an example, the first section may extend along one side of the product and the second section may extend further than the first section along another side of the product. In this way, differently shaped products (for example square or rectangular) can be sufficiently protected using the moulded

The moulded structure may be provided as a fixed unit having a shape formed directly from its moulding template. Alternatively, the moulded structure may be provided as an adjustable unit, such that the positions of the first and second sections relative to each other can be adjusted.

Whilst the shapes of the moulded structures can be designed to be product specific, the moulded structures may also be provided in different designs having different widths, lengths and depths in different paper thicknesses and paper types. This would allow a packaging designer to select for each surface or edge of their product, the moulded structure which is most applicable and provides the best fit to the product or the best protection. In an example, the moulded structures are provided as a mix of “standard” shapes which can be purchased on the open marked like a commodity, where they may have a product specific design, A packaging design can optimize the combination of different moulded structures by having many “standard” shaped moulded structures and a small number of product-specific designs requiring special mould-tooling. This would reduce the fixed one-time costs related to launching a new packaging design, Once the designer has selected the optimum moulded structure for and dimensions of the boxing for their product, the protective packaging can be optimised based on drop testing by changing some parameters, for example by applying different paper thicknesses or paper types, to find which is most suitable for the product in question. The moulded structures may be delivered, with different sizes or properties, as nested moulded structures. This would reduce the space for transporting the moulded structures and reduce transportation costs.

The moulded structures can be attached to paper-based packaging or a corrugated box to form the protective packaging. FIGS. 8A and 8B are schematics of protective packaging 800 according to some examples. In an example, the cushioning ribs may be attached using an interlocking arrangement, for example to form a cross,

The packaging to which the moulded structures are attached may be a half-opened corrugated box used to represent one of two end-caps for protecting a printer. The product can be provided with a left and right paper-based cushion to protect it during transportation or storage. In an example, the cushions can be attached to the packaging by gluing, stapling, or interlocking.

The moulded structures may alternatively, or additionally, be attached to an inner surface of the packaging such that they are arranged adjacent the product to be protected. FIGS. 8A and 8B show a protective packaging 800 in which moulded structures 810 are attached to a package 820. The moulded structures may be arranged on the inside of the protective packaging next to a product 830 contained within the packaging. An outer layer of packaging 840 may also be provided for further protection or reinforcement during storage or shipping,

The packaging may comprise an end-cap suitable for protecting a printing product. FIG. 8C is a schematic of an arrangement of moulded structures 810 for protecting a hardware product 830 according to an example. In this example, the product is surrounded by the moulded structures (the box or package to which the moulded structures are attached is not shown). The moulded structures protect the product at its edges or corners.

The moulded structures may be provided to conform to the shape of a product to be protected, for example as shown in FIG. 9. For example, a bottle may be packed by attaching two or more ribs to a corrugated sheet which is then rolled around the bottle. In this example, the corrugated sheet does not have to be formed and glued into a box.

In an example, the first and second sections are adjusted via a hinged region. In an example, a moulded structure may comprise more than one hinge.

FIGS. 10A-D are schematics of a moulded structure for protective packaging according to an example. As shown in FIG. 10A, the first and second sections may be of different lengths or sizes. FIG. 10B shows the moulded structure in an open configuration (as moulded). FIGS. 10C and 10D show the moulded structure in a closed configuration (adjusted). In an example, the moulded structure is moulded to be I-shaped and can be adjusted into an L-shaped form.

A shown in FIG. 10B, the structure comprises a first section 1010 having a recessed region 1015 and a second section 1020 having a recessed region 1025. Each recessed region is provided facing towards a product to be protected, with a shell forming the first and second sections facing outwards and away from the product such that the shell forming the first and second sections are the point of contact receiving an external impact force. The structure further comprises an intermediate section 1030 disposed between the first section and the second section. The moulded structure comprises an attachment surface 1040. An attachment surface may be formed at or around a periphery of the first section and second section. The intermediate section may comprise a hinge 1045 about which the first and/or second section can pivot. The intermediate section may comprise a sloped surface 1050 on the first section or first shell and a corresponding sloped surface 1060 on the second section or second shell. The attachment surface may comprise the sloped surfaces. In the example shown, when the first section is pivoted about the hinge the sloped surfaces 1050, 1060 connect, hence closing the open V-shape of the intermediate section. The intermediate section may comprise a recessed region to protect a corner of protective packaging. Connecting regions 1070, 1080 between the sloped surfaces and the attachment surfaces are provided and may have a surface that is suitable for conforming to a package or for attachment to a package, For example, when the moulded structure is in a closed configuration the inside corner may be suitable for hugging the corner of a package. In the open configuration, both the first and second sections extend along the same direction 1090.

FIGS. 10C and 10D show the moulded structure in a closed configuration in which the first section has been rotated about the hinge 1045. In the closed configuration, the second section extends along a first direction 1090 and the first section extends along a second direction 1095. The first direction may be substantially perpendicular to the second direction. The first section and second section may be linearly shaped with the intermediate section forming a corner between the first section and second section.

Each recessed region may define a hollow shell such that the moulded structure can be nested within a further moulded structure. FIGS. 11A and 11B are schematics showing the nesting or stacking of moulded structures according to examples.

The present disclosure provides environmental advantages with reduced manufacturing costs. The recessed regions of the moulded structures provide for a lighter shock absorber with lower material costs. Foam and EPS based packaging has already been banned by some environmental programs of selective countries, e.g. California, Italy, which push against the use of plastic-based packaging. Plastics packaging is being replaced by the use of moulded pulp but moulded pulp is a costly alternative to EPS because the pulp process starts with paper fibres in large amounts of water, where the water is sucked or pressed out and the remaining fibres use a significant amount of hot air drying. The pulping process is time-consuming and costly and further compounded by locations in areas with high relative humidity which do not support the drying process. The manufacturing techniques used for providing the moulded structures described herein allow for a reduction in energy used during manufacture, thus enabling a lower price per unit.

The present disclosure allows paper-based cushions to be manufactured or provided at a lower production cost. The cost of production is reduced because less energy is used during the manufacturing since the step of drying pulp, as used with existing methods, is removed. Much less heat energy is used using the paper-plate manufacturing technology. There is provided a faster moulding cycle with moulding times of around one second being achieved per mould (as opposed to one minute as with existing pulping techniques).

The present disclosure provides protective packaging that is more environmentally friendly and easier to recycle, Instead of using moulded pulp which has high energy consumption and manufacturing costs, paper-based plate technology is used to manufacture the moulded structures for protective packaging, where the moulded structures can be shaped to conform to product packaging.

The paper-based moulded structures described herein can possess similar material characteristics as the packaging to which they are attached. As such, the similar material used for both the inner and outer protection makes recycling easier and simpler because the moulded structures can be recycled with the outer packaging or corrugated boxing in the same paper recycling stream. The moulded structures according to the present disclosure therefore have a higher environmental perception than existing packaging.

While the method, apparatus and related aspects have been described with reference to certain examples, various modifications, changes, omissions, and substitutions can be made without departing from the spirit of the present disclosure. In particular, a feature or block from one example may be combined with or substituted by a feature/block of another example.

The word “comprising” does not exclude the presence of elements other than those listed in a claim, “a” or “an” does not exclude a plurality, and a single processor or other unit may fulfil the functions of several units recited in the claims.

The features of any dependent claim may be combined with the features of any of the independent claims or other dependent claims. 

1. A method of manufacturing a protective packaging structure comprising the steps of: providing a moulded structure comprising an attachment surface, the moulded structure including a recessed portion defining a shock absorbing region; applying the moulded structure to a packaging substrate using the attachment surface; and configuring the substrate to form the protective packaging structure.
 2. A method as claimed in claim 1, further comprising configuring the substrate whereby to conform to an outer dimension of an article to be packaged.
 3. A method as claimed in claim 1, further comprising the step of inserting a plurality of moulded structures into respective pre-positioned depressions in an assembly tray of a conveyer system or rotary table system.
 4. A method as claimed in claim 3, wherein the moulded structures are inserted manually by operators or automatically by robotic arms or dispensers,
 5. A method as claimed in claim 3 further comprising the step of applying adhesive to the attachment surfaces.
 6. A method as claimed in claim 5, wherein the flat sheet is pressed onto the attachment surfaces of the moulded structures.
 7. A method as claimed in claim 5, further comprising the step of folding the flat sheet to form a half-box having the moulded structures attached thereto.
 8. A method as claimed in claim 1, wherein the step of applying comprises one or more of: gluing; stapling; sandwiching; and interconnecting.
 9. A method as claimed in claim 8, wherein the moulded structures are glued onto the substrate in a flat-laying arrangement and are subsequently moved into a final position and orientation by folding the substrate.
 10. A protective packaging, the packaging comprising: a paper-based moulded structure, the moulded structure comprising an attachment surface and a recessed portion defining a shock absorbing region; and a substrate, wherein the attachment surface is arranged to secure the moulded structure to the packaging substrate.
 11. A protective packaging as claimed in claim 10, wherein the moulded structure comprises an intermediate section comprising at least one hinge that is alignable with a hinge on the substrate to enable joint pivoting.
 12. A protective packaging as claimed in claim 10, wherein the moulded structure comprises a first section and a second section and the attachment surface is formed at a periphery of the first section and second section.
 13. A protective packaging as claimed in claim 11, wherein the moulded structure can be pivoted about the hinge to form a substantially L-shaped structure.
 14. A protective packaging as claimed in claim 10, wherein the moulded structure is secured between two substrates.
 15. A protective packaging as claimed in claim 10, wherein the packaging is an end-cap suitable for protecting a printing product. 